On September 22, Genesis Products Inc. announced it supported the launch of the all-electric Coachmen RVEX by supplying an interior designed with lightweight composite materials that directly contribute to the vehicle’s 270-mile electric range.
Genesis said the project focused on reducing overall vehicle weight through material innovation.
The company reported a 45 percent reduction in cabinetry weight, saving more than 290 pounds, by combining its G-Lite plywood with LISOCORE®, a patented structural material.
Floors, ceilings, and walls were made 50 percent lighter compared with traditional oriented strand board or plywood by using G-Strong PET foam-core panels, according to a release.
“Coachmen came to us with the primary goal of reducing weight in the unit. We turned to innovative materials like our exclusive G-Lite plywood and our G-Strong PET foam-core panels to achieve our goals,” said Kyle Rasler, engineering manager at Genesis, in the September 22, 2025 press release.
The materials were also designed to enhance performance beyond weight savings. Genesis stated that the G-Strong panels absorb no moisture and double the R-value of wood alternatives.
Zach Eppers, general manager at Coachmen RV, added, “We couldn’t have done this without Genesis. They saw our vision and had not only the design and engineering capabilities, but also the drive to help bring it to fruition.”
The company reported that the new interior integrates high-performance vinyl surfaces in stone and woodgrain finishes and introduces features such as two pull-out pantries.
Genesis described the result as an interior that addresses both weight reduction and functionality.
The release did not disclose Coachmen’s production timeline or market rollout plans for the RVEX.
What it Means for RV Manufacturers and Suppliers
For RV manufacturers, Genesis’s approach underscores the importance of material selection in extending range for electric drivetrains, a factor that could influence design strategies for future models.
Weight savings at the component level may also affect homologation processes and integration with existing platforms, where lighter interiors could ease compliance with efficiency or emissions-related standards.
Suppliers to the RV industry may see increased demand for advanced lightweight materials, particularly those offering both durability and thermal performance.
Inventory planning could shift as OEMs request certified panels, foam-core structures, or similar alternatives to traditional plywood.
Standards for installation and after-sales support may also evolve as manufacturers adopt new components that require specialized handling or training for technicians.
As electrification advances, suppliers that can deliver lightweight, moisture-resistant, and thermally efficient components may position themselves more competitively.
Genesis’s contribution to the RVEX demonstrates a case study of how material innovation can directly impact range, production feasibility, and customer expectations in electric RV development.
Featured image by Genesis Products Inc.